1981 Kawasaki GPz550: Restoration

Rather than JB Weld I suggest an aluminum-based epoxy, such as Hypoxy Alumfast.

[nvr2old]

I'll bet JB Weld or Liquid steel would work great for that repair. Clean it well where the pieces meet and apply the JB to both parts before attaching. Maybe run the tap through one more time after it dries.

[srsupertrap]

I got a lot done today but ran into a problem on the cylinder head today. While removing the valve cover & cams a couple weeks back I found the valve cover bolt that goes thru the half moon gasket had previously cracked the head directly below the bolt. Pointer . . .


The bolt & threads were corroded so being careful I chased the threads with a M6 tap.



And as expected the fractured piece broke off. The valve cover bolt threads are barely visible at the top of the break & I believe the valve cover bolt can be tightened down. What I am concerned with is that bolt goes through the half moon gasket so it would likely leak oil unless sealed.

What do you think? Reassembly then RTV threaded area & Epoxy the little broken piece back into place

[Big T]

Try hot water (really hot), detergent (maybe simple Green) and a tooth brush

Dunk them in hot water/detergent mix for a few minutes, pull out scrub, rinse, repeat

Then dry them in/out with air hose

[srsupertrap]

High of 13F in Colorado Springs today. Here is one of the Flatslides disassembled. The needles are 5FL14 on the 3rd clip. Cleaned up very well by just spraying them down with Gumout.



Corey who is the Administrator on the GPz550 forum showed me this Carburetor schematic from a 1986 Suzuki Gsx-r750 (g). They are pretty close to what I have.

[srsupertrap]

Kinda waiting on different parts so today I removed the Fox Street Shox, the right side one was leaking but I think they might only need new seals and a thorough cleaning. I will find out when Evolution Suspension tears them down next week. A couple of pics to follow &

Carb cleaning residue? The Mikuni carb bodies have Berryman residue even though I sprayed them down with Gumout right after removing them from the dip tank? I think one gallon dates back to 2008 and may be too dirty? Any suggestions to remove the sticky Berryman residue?


The leaker





No fuss, just more money

[Big T]

Just found a ton of parts!

http://louisville.craigslist.org/mcy/4240087129.html

The 1981 is a one year only bike and almost no parts from an 85 interchange

[srsupertrap]

Looking good...

Re the 32.5 pilot jets, don't assume they are too big till you try them...33mm flatslides on a 550 won't have a lot of airspeed at small openings. I've run bigger pilots on bored GSXR flatslides on 750's...Speedway TQ's actually which must respond in a single gear so do get run rich low down, but the principal is the same.

Those carbs probably are the GSXR750 racekit carbs - or what were sold as kit carbs...Midway between the road GSXR carbs and the RS series which came a year or so later.

GregT,
I believe you are correct. Corey Clough on the GPz550 forum has a set of these same Carbs and when I asked him if he could check, he replied the Pilots were #35 while the mains were 117.5's.

These "GSXR750 racekit carbs" use the same Mikuni pilot jet as the GS1000/750 VM series carbs and those pilots were #15 from the factory. These carbs also do not have a fuel screw like the RS34s on my GS1100 2V. If nothing else they are rare. Hope they work good

Just found a ton of parts!.

Thanks for looking out for me 83GS1100E_Tornado, I appreciate it. That one is a little far but if you come across a 1981 let me know because I am searching for an OEM seat & maybe a Bassani too.

Just found a ton of parts!

http://louisville.craigslist.org/mcy/4240087129.html

[GregT]

Looking good...

Re the 32.5 pilot jets, don't assume they are too big till you try them...33mm flatslides on a 550 won't have a lot of airspeed at small openings. I've run bigger pilots on bored GSXR flatslides on 750's...Speedway TQ's actually which must respond in a single gear so do get run rich low down, but the principal is the same.

Those carbs probably are the GSXR750 racekit carbs - or what were sold as kit carbs...Midway between the road GSXR carbs and the RS series which came a year or so later.

[srsupertrap]

Hi Ray,
Thanks for helping out . . . BTW how is your GS1000S doing. Planning to take a New Years Day ride?

Steve


Back to the Carbs, a GSer mentioned how good Simple Green is for cleaning. I cleaned the outside of the carbs and I agree.



#1 goes into the tank


Shipped out my valve shims today to Corey who is the Administrator on The GPz550 Forum.

Hi Steve, The clearances will get tighter as the seats wear. Ray

[srsupertrap]

I keep forgetting which way do DOHC valve/bucket shims wear over time? Looking at the photo can I expect the Ex .007" to become tighter/looser over the next thousands of miles?

Thanks

[srsupertrap]

I want to thank Peter (madmito) a brand new member on The GPz550 forum for posting the Moriwaki KZ550 Cam Installation Instructions. That gives me the valve lash to set both my GPz550 cams to (.005 to .007"). Second he still has the cams in the box (See Below).

If he measures the cam lobe lift I can compare that measurement to the 8.25mm reading I measured on the Moriwaki Cams installed in my GPz550 which eliminates the need to measure cam duration & determine opening & closing numbers. Then I can focus on degreeing the cams.





That's madmito . . . looks like Dainese Leathers

Good god. Those aren't like rebuilding a set of VM's, that's for sure. Looks like you're doing a top end rebuild on an engine I can see why you're taking all the photos. Sure enjoying the thread so far, thanks.